EP1542021A2 - Sensor housing with integral mounting piece - Google Patents
Sensor housing with integral mounting piece Download PDFInfo
- Publication number
- EP1542021A2 EP1542021A2 EP20040257673 EP04257673A EP1542021A2 EP 1542021 A2 EP1542021 A2 EP 1542021A2 EP 20040257673 EP20040257673 EP 20040257673 EP 04257673 A EP04257673 A EP 04257673A EP 1542021 A2 EP1542021 A2 EP 1542021A2
- Authority
- EP
- European Patent Office
- Prior art keywords
- mounting piece
- magneto
- shell
- conversion element
- electricity conversion
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 238000006243 chemical reaction Methods 0.000 claims abstract description 37
- 239000011347 resin Substances 0.000 claims abstract description 33
- 229920005989 resin Polymers 0.000 claims abstract description 33
- 230000005291 magnetic effect Effects 0.000 claims abstract description 28
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 238000000034 method Methods 0.000 claims 2
- 238000000465 moulding Methods 0.000 description 11
- 239000004020 conductor Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 230000004907 flux Effects 0.000 description 2
- 230000000295 complement effect Effects 0.000 description 1
- 230000005294 ferromagnetic effect Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
Images
Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01P—MEASURING LINEAR OR ANGULAR SPEED, ACCELERATION, DECELERATION, OR SHOCK; INDICATING PRESENCE, ABSENCE, OR DIRECTION, OF MOVEMENT
- G01P1/00—Details of instruments
- G01P1/02—Housings
- G01P1/026—Housings for speed measuring devices, e.g. pulse generator
-
- G—PHYSICS
- G01—MEASURING; TESTING
- G01P—MEASURING LINEAR OR ANGULAR SPEED, ACCELERATION, DECELERATION, OR SHOCK; INDICATING PRESENCE, ABSENCE, OR DIRECTION, OF MOVEMENT
- G01P3/00—Measuring linear or angular speed; Measuring differences of linear or angular speeds
- G01P3/42—Devices characterised by the use of electric or magnetic means
- G01P3/44—Devices characterised by the use of electric or magnetic means for measuring angular speed
- G01P3/443—Devices characterised by the use of electric or magnetic means for measuring angular speed mounted in bearings
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C19/00—Bearings with rolling contact, for exclusively rotary movement
- F16C19/02—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows
- F16C19/14—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows for both radial and axial load
- F16C19/18—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows for both radial and axial load with two or more rows of balls
- F16C19/181—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows for both radial and axial load with two or more rows of balls with angular contact
- F16C19/183—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows for both radial and axial load with two or more rows of balls with angular contact with two rows at opposite angles
- F16C19/184—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows for both radial and axial load with two or more rows of balls with angular contact with two rows at opposite angles in O-arrangement
- F16C19/186—Bearings with rolling contact, for exclusively rotary movement with bearing balls essentially of the same size in one or more circular rows for both radial and axial load with two or more rows of balls with angular contact with two rows at opposite angles in O-arrangement with three raceways provided integrally on parts other than race rings, e.g. third generation hubs
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C2326/00—Articles relating to transporting
- F16C2326/01—Parts of vehicles in general
- F16C2326/02—Wheel hubs or castors
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C33/00—Parts of bearings; Special methods for making bearings or parts thereof
- F16C33/72—Sealings
- F16C33/723—Shaft end sealing means, e.g. cup-shaped caps or covers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16C—SHAFTS; FLEXIBLE SHAFTS; ELEMENTS OR CRANKSHAFT MECHANISMS; ROTARY BODIES OTHER THAN GEARING ELEMENTS; BEARINGS
- F16C41/00—Other accessories, e.g. devices integrated in the bearing not relating to the bearing function as such
- F16C41/007—Encoders, e.g. parts with a plurality of alternating magnetic poles
Definitions
- This invention relates to a magnetic variation sensor which can be used as a rotational speed sensor such as a vehicle wheel speed sensor or an engine revolution sensor, and a method of manufacturing such a sensor.
- a vehicle anti-lock brake system needs wheel speed sensors to detect wheel speeds.
- Typical such wheel speed sensors are magnetic variation sensors.
- Fig. 7 shows a magnetic variation sensor comprising a sensor unit a for picking up variations in the magnetic flux produced by a ring member B mounted on a portion of a vehicle that rotates together with a vehicle wheel and converting such variations in the magnetic flux into electric signals, and a mounting portion b at which the sensor P is mounted to a stationary part of the vehicle near the ring member B.
- the sensor unit a may be a Hall IC 1 comprising a Hall element (magneto-electricity conversion element) and a signal processing circuit, or may comprise a coil wound around a bobbin, a pole piece inserted in the bobbin, and a magnet provided at the rear end of the pole piece, as disclosed in (unexamined) JP patent publication 2001-174471.
- the Hall IC picks up variations in the bias magnetic field produced by the ring member B when the ring member B rotates together with the vehicle wheel and converts such variations in the magnetic field into electric signals.
- the sensor P has a magnet and the ring member B is formed of a non-magnetized ferromagnetic (such as iron) encoder.
- the ring member or encoder B is magnetized such that N and S poles circumferentially alternate with each other. In this case, the magnet of the sensor P is omitted.
- a resin shell 5 is formed by molding so as to enclose the sensor unit a and the portion of the cable 4 connected to the sensor unit a .
- a portion of the resin is formed into a mounting piece 6 that is integral with the shell 5.
- the sensor P is adapted to be mounted to a vehicle by fastening the mounting piece 6 to a stationary part D of the vehicle by means of e.g. a screw. If the screw is in direct engagement with the mounting piece 6, which is made of a resin, the screw cannot be tightened with sufficient force because the resin forming the mounting piece 6 is low in strength.
- (unexamined) JP patent publication 2000-171475 proposes to form a screw (or bolt) hole by embedding a metallic ring 16 in the resin when forming the mounting piece 6 by molding.
- the mounting piece 6 is inclined at a predetermined angle with respect to the height direction (direction perpendicular to the plane containing the sheet of Fig. 7) of the sensor unit a according to the position of a stationary part of the vehicle to which the sensor P is to be mounted.
- the shell 5 and the mounting piece 6 cannot be formed simultaneously but have to be formed in separate stages as disclosed in JP patent publication 2000-171475.
- the manufacturing cost is thus high.
- JP patent publication 2003-307523 proposes to form the shell 5 by molding a resin with a portion of a separate member as the mounting piece 6 embedded in the resin so as to form a predetermined angle with respect to the thickness direction of the sensor unit a .
- the mounting piece 6 can thus be secured to the shell 5 simultaneously when the shell 5 is formed by molding. But in this arrangement, it is necessary to provide a metallic case in the mold assembly to protect the sensor unit a and also to hold the separate mounting piece 6 in a predetermined angular position when forming the shell by molding a resin. The mold assembly is thus expensive.
- An object of the invention is to provide an improved magnetic variation sensor and a method of manufacturing a magnetic variation sensor which makes it possible to form a mounting piece having any desired angle with respect to the shell at a low cost.
- a magnetic variation sensor comprising a magneto-electricity conversion element for picking up variations in magnetic fields and converting the variations picked up into electric signals, a cable connected to the magneto-electricity conversion element, a resin shell enclosing the magneto-electricity conversion element and a portion of the cable where the cable is connected to the magneto-electricity conversion element, and a mounting piece in the form of a metallic plate secured to the shell with a portion of the mounting piece embedded in the shell, the portion of the mounting piece being formed with a hole through which the cable passes, the hole being provided with an arrangement for preventing the mounting piece from rotating relative to the shell.
- the mounting piece will never rotate about the axis of the shell under external forces such as vibrations.
- the hole includes a radial recess formed in the outer circumference of the hole, the recess being filled with a portion of the resin forming the shell, whereby the resin filling the recess serves to prevent the mounting piece from rotating relative to the shell.
- the recess has preferably a radially outwardly increasing circumferential width.
- the mounting piece can be rigidly secured to the shell with the least possibility of rotating about the shell.
- the hole has a cutout extending to an outer edge of the mounting piece, whereby the cable can be easily pushed into the hole through the cutout.
- the magnetic variation sensor further comprises a holder supporting the magneto-electricity conversion element and embedded in the shell, the magneto-electricity conversion element having terminals connected to the cable, the holder being embedded in the shell together with the magneto-electricity conversion element.
- a method of manufacturing a magnetic variation sensor comprising the steps of placing a magneto-electricity conversion element for picking up variations in magnetic fields in a mold assembly, holding the magneto-electricity conversion element temporarily in position in the mold assembly, placing a mounting piece in the form of a metallic plate in the mold assembly, holding the mounting piece temporarily in position by bringing at least part of the mounting piece into contact with an inner wall of the mold assembly, pouring a resin into the mold assembly so that the magneto-electricity conversion element and a portion of the mounting piece are embedded in the resin, and allowing the resin to harden, thereby forming a shell enclosing the magneto-electricity element and supporting the mounting plate.
- the magneto-electricity conversion element is supported on a holder and temporarily held in position in the mold assembly together with the holder.
- the mounting piece has at least two side edges, wherein the mold assembly comprises an upper mold, a lower mold and a pair of partial molds each detachably coupled to one of the upper and lower molds, the mounting piece being temporarily held in position in the mold assembly by bringing each of the two side edges into contact with an inner wall of one of the partial molds.
- the mounting piece since the two side edges of the mounting piece are temporarily held in position by partial molds while the shell is being formed by molding a resin, the mounting piece can be stably held in position.
- the sensor unit When the shell is formed by molding a resin, the sensor unit is supported by the holder, and the mounting piece is temporarily held in position by partial molds at any desired inclination angle with respect to the sensor element. Thus, it is not necessary to use a metallic case as needed in JP patent publication 2003-307523.
- the sensor of this embodiment is a wheel speed sensor P including, as shown in Figs. 1 and 2, a sensor unit a comprising a magneto-electricity conversion element 1 such as a Hall IC supported by a holder 2.
- the sensor unit a is embedded in a shell 5 which is formed by molding a resin after connecting conductors 4a of a cable 4 to respective lead terminals 3 of the magneto-electricity conversion element 1.
- a plate-shaped metallic mounting piece 6 is partly embedded in the resin so that the mounting piece 6 is securely joined to the shell 5 as shown.
- the sensor P is mounted to a vehicle body by securing the mounting piece 6 to a stationary member D of the vehicle body.
- the magneto-electricity conversion element 1 is embedded in the shell 5 together with the plate-shaped terminals 3.
- the terminals 3 are each formed with a hole 7.
- the magneto-electricity conversion element 1 is received in a recess 8 formed in the holder 2.
- the recess 8 is slightly larger than the element 1 so that the element 1 can be received in the recess 8 even if the element 1 is slightly oversized.
- the holder 2 has protrusions 9 adapted to engage in the holes 7 formed in the terminals 3 when the element 1 is received in the recess 8. With the protrusions 9 engaged in the holes 7, the terminals 3 and thus the magneto-electricity conversion element 1 are held in position.
- the conductors 4a of the cable 4 are soldered or welded to the respective terminals 3 before or after the magneto-electricity conversion element 1 has been received in the recess 8 of the holder 2.
- the sensor unit a i.e. the magneto-electricity conversion element 1 is set in molds 20 together with the holder 2, and a resin is poured into the molds 20 to form the shell 5.
- the wheel speed sensor P is thus formed.
- the mounting piece 6 may be a rectangular plate as shown in Fig. 3A, a triangular plate or of any other shape.
- the mounting piece 6 is formed with a screw (or bolt) hole 11 and a hole 12 through which the cable 4 passes. Along the edge of the hole 12, radially outwardly widening recesses 13 are formed.
- part of the resin fills the recesses 13, thus preventing the mounting piece 6 from rotating relative to the shell 5. Since the recesses 13 are radially outwardly widening recesses, once the resin filling the recesses 13 hardens, it can never come out of the recesses 13. Thus, the mounting piece 6 is prevented from not only rotating but from coming out of the shell 5. It does not move relative to the shell, either.
- the shell 5 may be molded with the mounting piece 6 inclined at any desired angle with respect to the height direction of the sensor unit a .
- the upper and lower molds 20 used to mold the shell 5 may each include a partial mold 21 inserted in the mold 20 so as to be detachable therefrom.
- the partial molds 21 of the upper and lower molds 20 are formed with cavities 22 that are inclined at a predetermined angle or not inclined with respect to the height direction of the sensor unit a so that the mounting piece 6 can be received in the cavities 22.
- a plurality of sets of such partial molds 21 are prepared, each set being formed with cavities 22 inclined at a different angle from the cavities 22 of the other sets. According to the desired inclination angle of the mounting piece 6 with respect to the height direction of sensor unit a , a suitable partial mold set is selected and mounted to the upper and lower molds 20.
- the mounting piece 6 is a rectangular plate, a plurality of sets of partial molds 21 are prepared, each set being formed with cavities 22 having sides complementary to the long and short sides 6a and 6b of the rectangle and inclined at a different angle from the cavities 22 of the other set.
- a desired partial mold set is selected and mounted to the upper and lower molds 20.
- the mounting piece 6 is set in the molds 20 together with the sensor unit a and other parts so that its long and short sides 6a and 6b are supported on the corresponding sides of the cavities 22.
- the mounting piece 6 can thus be set stably and accurately in the molds.
- the hole 12 formed in the mounting piece 6 is preferably non-circular so that the mounting piece 6 cannot rotate relative to the shell 5.
- the hole 12 may have a polygonal (such as hexagonal) cross-section as shown in Fig. 4A.
- the hole 12 may have a cutout 14 extending to one side edge of the mounting piece 6 so that the cable 4 can be pushed through the cutout 14 into the hole 12 as shown by the arrow (in phantom line) in Fig. 4B.
- the wheel speed sensor P is mounted on a stationary part of a vehicle so that the magneto-electricity conversion element 1 opposes a target member B such as a sensor rotor mounted on an axle.
- a target member B such as a sensor rotor mounted on an axle.
- the magneto-electricity conversion element 1 picks up variations in the magnetic field produced by the target member B corresponding to the rotational speed of the target member B and converts the variations in the magnetic field into electric signals.
- the electric signals are transmitted through the terminals 3 and the cable 4 and entered into a control unit of e.g. an ABS. Based on the signals, the control unit detects (calculates) the rpm of the target member B and thus the rpm of the vehicle wheel.
- the magneto-electricity conversion element of the embodiment is a Hall IC, it may be an electromagnetic pickup using a coil.
- the magnetic variation sensor of the invention is not limited to a wheel speed sensor but may be a different type of sensor.
- the wheel speed sensor P is mounted on a vehicle in the same manner as conventional wheel speed sensors.
- the sensor unit a is an electromagnetic pickup
- the sensor P is preferably mounted on a hub cap D so that its longitudinal axis extends perpendicular to the axis c of a wheel hub H with its sensor unit a opposing the sensor rotor B, which is coaxially mounted on the wheel hub H.
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- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Transmission And Conversion Of Sensor Element Output (AREA)
- Measuring Magnetic Variables (AREA)
Abstract
Description
- This invention relates to a magnetic variation sensor which can be used as a rotational speed sensor such as a vehicle wheel speed sensor or an engine revolution sensor, and a method of manufacturing such a sensor.
- A vehicle anti-lock brake system (ABS) needs wheel speed sensors to detect wheel speeds. Typical such wheel speed sensors are magnetic variation sensors. Fig. 7 shows a magnetic variation sensor comprising a sensor unit a for picking up variations in the magnetic flux produced by a ring member B mounted on a portion of a vehicle that rotates together with a vehicle wheel and converting such variations in the magnetic flux into electric signals, and a mounting portion b at which the sensor P is mounted to a stationary part of the vehicle near the ring member B. The sensor unit a may be a
Hall IC 1 comprising a Hall element (magneto-electricity conversion element) and a signal processing circuit, or may comprise a coil wound around a bobbin, a pole piece inserted in the bobbin, and a magnet provided at the rear end of the pole piece, as disclosed in (unexamined) JP patent publication 2001-174471. - If the wheel speed sensor P is of the type including the
Hall IC 1, the Hall IC picks up variations in the bias magnetic field produced by the ring member B when the ring member B rotates together with the vehicle wheel and converts such variations in the magnetic field into electric signals. In order to produce such variations in the magnetic field corresponding to the rotational speed of the ring member B and thus the vehicle wheel, the sensor P has a magnet and the ring member B is formed of a non-magnetized ferromagnetic (such as iron) encoder. Alternatively, the ring member or encoder B is magnetized such that N and S poles circumferentially alternate with each other. In this case, the magnet of the sensor P is omitted. - As shown in Fig. 7, with a
cable 4 connected to the sensor unit a, aresin shell 5 is formed by molding so as to enclose the sensor unit a and the portion of thecable 4 connected to the sensor unit a. When forming theshell 5 by molding a resin, a portion of the resin is formed into amounting piece 6 that is integral with theshell 5. The sensor P is adapted to be mounted to a vehicle by fastening themounting piece 6 to a stationary part D of the vehicle by means of e.g. a screw. If the screw is in direct engagement with themounting piece 6, which is made of a resin, the screw cannot be tightened with sufficient force because the resin forming themounting piece 6 is low in strength. Thus, (unexamined) JP patent publication 2000-171475 proposes to form a screw (or bolt) hole by embedding ametallic ring 16 in the resin when forming themounting piece 6 by molding. - The
mounting piece 6 is inclined at a predetermined angle with respect to the height direction (direction perpendicular to the plane containing the sheet of Fig. 7) of the sensor unit a according to the position of a stationary part of the vehicle to which the sensor P is to be mounted. - In this arrangement, the
shell 5 and themounting piece 6 cannot be formed simultaneously but have to be formed in separate stages as disclosed in JP patent publication 2000-171475. The manufacturing cost is thus high. - JP patent publication 2003-307523 (unexamined) proposes to form the
shell 5 by molding a resin with a portion of a separate member as themounting piece 6 embedded in the resin so as to form a predetermined angle with respect to the thickness direction of the sensor unit a. - The
mounting piece 6 can thus be secured to theshell 5 simultaneously when theshell 5 is formed by molding. But in this arrangement, it is necessary to provide a metallic case in the mold assembly to protect the sensor unit a and also to hold theseparate mounting piece 6 in a predetermined angular position when forming the shell by molding a resin. The mold assembly is thus expensive. - An object of the invention is to provide an improved magnetic variation sensor and a method of manufacturing a magnetic variation sensor which makes it possible to form a mounting piece having any desired angle with respect to the shell at a low cost.
- According to this invention, there is provided a magnetic variation sensor comprising a magneto-electricity conversion element for picking up variations in magnetic fields and converting the variations picked up into electric signals, a cable connected to the magneto-electricity conversion element, a resin shell enclosing the magneto-electricity conversion element and a portion of the cable where the cable is connected to the magneto-electricity conversion element, and a mounting piece in the form of a metallic plate secured to the shell with a portion of the mounting piece embedded in the shell, the portion of the mounting piece being formed with a hole through which the cable passes, the hole being provided with an arrangement for preventing the mounting piece from rotating relative to the shell.
- Because the hole through which the cable passes has a non-circular shape, the mounting piece will never rotate about the axis of the shell under external forces such as vibrations.
- Since the mounting piece itself is formed of a metal, it is not necessary to use the ring disclosed in JP patent publication 2000-171475.
- Preferably, the hole includes a radial recess formed in the outer circumference of the hole, the recess being filled with a portion of the resin forming the shell, whereby the resin filling the recess serves to prevent the mounting piece from rotating relative to the shell. The recess has preferably a radially outwardly increasing circumferential width.
- With this arrangement, the mounting piece can be rigidly secured to the shell with the least possibility of rotating about the shell.
- Preferably, the hole has a cutout extending to an outer edge of the mounting piece, whereby the cable can be easily pushed into the hole through the cutout.
- Preferably, the magnetic variation sensor further comprises a holder supporting the magneto-electricity conversion element and embedded in the shell, the magneto-electricity conversion element having terminals connected to the cable, the holder being embedded in the shell together with the magneto-electricity conversion element.
- From another aspect of the invention, there is provided a method of manufacturing a magnetic variation sensor comprising the steps of placing a magneto-electricity conversion element for picking up variations in magnetic fields in a mold assembly, holding the magneto-electricity conversion element temporarily in position in the mold assembly, placing a mounting piece in the form of a metallic plate in the mold assembly, holding the mounting piece temporarily in position by bringing at least part of the mounting piece into contact with an inner wall of the mold assembly, pouring a resin into the mold assembly so that the magneto-electricity conversion element and a portion of the mounting piece are embedded in the resin, and allowing the resin to harden, thereby forming a shell enclosing the magneto-electricity element and supporting the mounting plate.
- Preferably, the magneto-electricity conversion element is supported on a holder and temporarily held in position in the mold assembly together with the holder. Preferably, the mounting piece has at least two side edges, wherein the mold assembly comprises an upper mold, a lower mold and a pair of partial molds each detachably coupled to one of the upper and lower molds, the mounting piece being temporarily held in position in the mold assembly by bringing each of the two side edges into contact with an inner wall of one of the partial molds.
- With this arrangement, since the two side edges of the mounting piece are temporarily held in position by partial molds while the shell is being formed by molding a resin, the mounting piece can be stably held in position.
- When the shell is formed by molding a resin, the sensor unit is supported by the holder, and the mounting piece is temporarily held in position by partial molds at any desired inclination angle with respect to the sensor element. Thus, it is not necessary to use a metallic case as needed in JP patent publication 2003-307523.
- Other features and objects of the present invention will become apparent from the following description made with reference to the accompanying drawings.
- Preferred embodiments of the present invention will now be described by way of example only with reference to the accompanying drawings, in which:
- Fig. 1 is a partially cutaway front view of an embodiment of the present invention;
- Fig. 2 is a partially cutaway plan view of the embodiment of Fig. 1;
- Fig. 3A is a plan view of a mounting piece used in the embodiment of Fig. 1;
- Fig. 3B is a plan view of the mounting piece, as mounted at different inclination angles about the axis of the sensor;
- Figs. 4A and 4B are plan views of different mounting pieces;
- Fig. 5 shows how the sensor according to the present invention is manufactured in a mold assembly;
- Fig. 6 shows how the sensor according to the present invention is mounted on a wheel hub; and
- Fig. 7 is a partially cutaway front view of a conventional such sensor.
-
- Now referring to Figs. 1-3, the sensor of this embodiment is a wheel speed sensor P including, as shown in Figs. 1 and 2, a sensor unit a comprising a magneto-
electricity conversion element 1 such as a Hall IC supported by aholder 2. The sensor unit a is embedded in ashell 5 which is formed by molding a resin after connectingconductors 4a of acable 4 torespective lead terminals 3 of the magneto-electricity conversion element 1. When molding the resin to form theshell 5, a plate-shapedmetallic mounting piece 6 is partly embedded in the resin so that themounting piece 6 is securely joined to theshell 5 as shown. The sensor P is mounted to a vehicle body by securing themounting piece 6 to a stationary member D of the vehicle body. - As shown in Figs. 1 and 2 and as described above, the magneto-
electricity conversion element 1 is embedded in theshell 5 together with the plate-shaped terminals 3. Theterminals 3 are each formed with ahole 7. The magneto-electricity conversion element 1 is received in arecess 8 formed in theholder 2. Therecess 8 is slightly larger than theelement 1 so that theelement 1 can be received in therecess 8 even if theelement 1 is slightly oversized. Theholder 2 hasprotrusions 9 adapted to engage in theholes 7 formed in theterminals 3 when theelement 1 is received in therecess 8. With theprotrusions 9 engaged in theholes 7, theterminals 3 and thus the magneto-electricity conversion element 1 are held in position. - The
conductors 4a of thecable 4 are soldered or welded to therespective terminals 3 before or after the magneto-electricity conversion element 1 has been received in therecess 8 of theholder 2. With theelement 1 received in theholder 2 and theconductors 4a connected to theterminals 3, the sensor unit a, i.e. the magneto-electricity conversion element 1 is set inmolds 20 together with theholder 2, and a resin is poured into themolds 20 to form theshell 5. The wheel speed sensor P is thus formed. - The
mounting piece 6 may be a rectangular plate as shown in Fig. 3A, a triangular plate or of any other shape. Themounting piece 6 is formed with a screw (or bolt)hole 11 and ahole 12 through which thecable 4 passes. Along the edge of thehole 12, radially outwardly wideningrecesses 13 are formed. When molding a resin to form theshell 5, part of the resin fills therecesses 13, thus preventing the mountingpiece 6 from rotating relative to theshell 5. Since therecesses 13 are radially outwardly widening recesses, once the resin filling therecesses 13 hardens, it can never come out of therecesses 13. Thus, the mountingpiece 6 is prevented from not only rotating but from coming out of theshell 5. It does not move relative to the shell, either. - As shown by chain line in Fig. 3B, the
shell 5 may be molded with the mountingpiece 6 inclined at any desired angle with respect to the height direction of the sensor unit a. - As shown in Fig. 5, the upper and
lower molds 20 used to mold theshell 5 may each include apartial mold 21 inserted in themold 20 so as to be detachable therefrom. Thepartial molds 21 of the upper andlower molds 20 are formed withcavities 22 that are inclined at a predetermined angle or not inclined with respect to the height direction of the sensor unit a so that the mountingpiece 6 can be received in thecavities 22. A plurality of sets of suchpartial molds 21 are prepared, each set being formed withcavities 22 inclined at a different angle from thecavities 22 of the other sets. According to the desired inclination angle of the mountingpiece 6 with respect to the height direction of sensor unit a, a suitable partial mold set is selected and mounted to the upper andlower molds 20. - If the mounting
piece 6 is a rectangular plate, a plurality of sets ofpartial molds 21 are prepared, each set being formed withcavities 22 having sides complementary to the long andshort sides cavities 22 of the other set. To mold theshell 5, a desired partial mold set is selected and mounted to the upper andlower molds 20. The mountingpiece 6 is set in themolds 20 together with the sensor unit a and other parts so that its long andshort sides cavities 22. The mountingpiece 6 can thus be set stably and accurately in the molds. - The
hole 12 formed in the mountingpiece 6 is preferably non-circular so that the mountingpiece 6 cannot rotate relative to theshell 5. For example, thehole 12 may have a polygonal (such as hexagonal) cross-section as shown in Fig. 4A. As shown in Fig. 4B, thehole 12 may have acutout 14 extending to one side edge of the mountingpiece 6 so that thecable 4 can be pushed through thecutout 14 into thehole 12 as shown by the arrow (in phantom line) in Fig. 4B. - As shown in Fig. 1, the wheel speed sensor P is mounted on a stationary part of a vehicle so that the magneto-
electricity conversion element 1 opposes a target member B such as a sensor rotor mounted on an axle. When the target member B rotates, the magneto-electricity conversion element 1 picks up variations in the magnetic field produced by the target member B corresponding to the rotational speed of the target member B and converts the variations in the magnetic field into electric signals. The electric signals are transmitted through theterminals 3 and thecable 4 and entered into a control unit of e.g. an ABS. Based on the signals, the control unit detects (calculates) the rpm of the target member B and thus the rpm of the vehicle wheel. - While the magneto-electricity conversion element of the embodiment is a Hall IC, it may be an electromagnetic pickup using a coil. The magnetic variation sensor of the invention is not limited to a wheel speed sensor but may be a different type of sensor.
- The wheel speed sensor P is mounted on a vehicle in the same manner as conventional wheel speed sensors. For example, especially if the sensor unit a is an electromagnetic pickup, the sensor P is preferably mounted on a hub cap D so that its longitudinal axis extends perpendicular to the axis c of a wheel hub H with its sensor unit a opposing the sensor rotor B, which is coaxially mounted on the wheel hub H.
Claims (8)
- A magnetic variation sensor comprising a magneto-electricity conversion element for picking up variations in magnetic fields and converting the variations picked up into electric signals, a cable connected to said magneto-electricity conversion element, a resin shell enclosing said magneto-electricity conversion element and a portion of said cable where said cable is connected to said magneto-electricity conversion element, and a mounting piece in the form of a metallic plate secured to said shell with a portion of said mounting piece embedded in said shell, said portion of said mounting piece being formed with a hole through which said cable passes, said hole having a non-circular cross-section, whereby said mounting piece is prevented from rotating relative to said shell.
- A magnetic variation sensor as claimed in claim 1 wherein said hole includes a radial recess formed in the outer circumference of said hole, said recess being filled with a portion of the resin forming said shell, whereby the resin filling said recess serves to prevent said mounting piece from rotating relative to said shell.
- A magnetic variation sensor as claimed in claim 2 wherein said recess has a radially outwardly increasing circumferential width.
- A magnetic variation sensor as claimed in any one of the preceding claims wherein said hole has a cutout extending to an outer edge of said mounting piece, whereby said cable can be pushed into said hole through said cutout.
- A magnetic variation sensor as claimed in any one of the preceding claims further comprising a holder supporting said magneto-electricity conversion element and embedded in said shell, said magneto-electricity conversion element having terminals connected to said cable, said holder being embedded in said shell together with said magneto-electricity conversion element.
- A method of manufacturing a magnetic variation sensor comprising:placing a magneto-electricity conversion element for picking up variations in magnetic fields in a mold assembly;holding said magneto-electricity conversion element temporarily in position in said mold assembly;placing a mounting piece in the form of a metallic plate in said mold assembly;holding said mounting piece temporarily in position by bringing at least part of said mounting piece into contact with an inner wall of said mold assembly;pouring a resin into said mold assembly so that said magneto-electricity conversion element and a portion of said mounting piece are embedded in said resin; andallowing said resin to harden, thereby forming a shell enclosing said magneto-electricity element and supporting said mounting plate.
- A method as claimed in claim 6 wherein said magneto-electricity conversion element is supported on a holder and temporarily held in position in said mold assembly together with said holder.
- A method as claimed in claim 6 or claim 7 wherein said mounting piece has at least two side edges, wherein said mold assembly comprises an upper mold, a lower mold and a pair of partial molds each detachably coupled to one of said upper and lower molds, said mounting piece being temporarily held in position in said mold assembly by bringing each of said two side edges into contact with an inner wall of one of said partial molds.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP2003415103A JP2005172687A (en) | 2003-12-12 | 2003-12-12 | Detecting sensor of magnetic variable |
JP2003415103 | 2003-12-12 |
Publications (2)
Publication Number | Publication Date |
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EP1542021A2 true EP1542021A2 (en) | 2005-06-15 |
EP1542021A3 EP1542021A3 (en) | 2005-07-13 |
Family
ID=34510567
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP20040257673 Withdrawn EP1542021A3 (en) | 2003-12-12 | 2004-12-09 | Sensor housing with integral mounting piece |
Country Status (4)
Country | Link |
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US (1) | US7250755B2 (en) |
EP (1) | EP1542021A3 (en) |
JP (1) | JP2005172687A (en) |
CN (1) | CN100465646C (en) |
Families Citing this family (12)
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FR2856145B1 (en) * | 2003-06-16 | 2005-09-02 | Michelin Soc Tech | DETECTION OF THE REVOLUTIONS OF A PNEUMATIC ASSEMBLY AND WHEEL, USING THE TERRESTRIAL MAGNETIC FIELD. |
JP4085079B2 (en) * | 2004-07-20 | 2008-04-30 | 住電エレクトロニクス株式会社 | Rotation detection sensor |
DE102006033931A1 (en) * | 2006-07-21 | 2008-01-24 | Robert Bosch Gmbh | Rotating movements measuring device for wheel bearing of motor vehicle, has carrier exhibiting paramagnetic or diamagnetic metallic retaining ring, with which metallic connecting unit is locked at sensor module |
JP4964109B2 (en) * | 2007-12-14 | 2012-06-27 | 住電エレクトロニクス株式会社 | Rotation detection sensor |
JP2009276286A (en) * | 2008-05-16 | 2009-11-26 | Nsk Ltd | Rolling bearing unit with device for measuring physical quantity |
JP5434688B2 (en) | 2009-09-24 | 2014-03-05 | 日立金属株式会社 | Resin mold structure with cable |
US9157970B2 (en) * | 2011-04-05 | 2015-10-13 | Ford Global Technologies, Llc | Method and apparatus for preventing contamination from affecting magnetic field sensors |
JP5633752B2 (en) * | 2011-10-28 | 2014-12-03 | 株式会社デンソー | Rotation detector |
KR102097936B1 (en) * | 2013-11-19 | 2020-04-07 | 현대모비스 주식회사 | Integrated Wheel Speed Measuring Device |
DE102014208510A1 (en) | 2014-05-07 | 2015-11-12 | Bayerische Motoren Werke Aktiengesellschaft | sensor ring |
DE102014013312A1 (en) * | 2014-09-08 | 2016-03-10 | Wabco Gmbh | Support for a sensor element, component group and speed sensor |
CN111765841A (en) * | 2020-07-01 | 2020-10-13 | 清华四川能源互联网研究院 | Non-contact angle displacement sensor based on giant magnetoresistance effect and measurement method |
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Also Published As
Publication number | Publication date |
---|---|
CN1627080A (en) | 2005-06-15 |
US7250755B2 (en) | 2007-07-31 |
EP1542021A3 (en) | 2005-07-13 |
JP2005172687A (en) | 2005-06-30 |
US20050127904A1 (en) | 2005-06-16 |
CN100465646C (en) | 2009-03-04 |
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